Graco 306518ZAC User's Manual
Contents
1. e The low level cut off valve accessory K closes the pump fluid intake when the fluid level is low which prevents air from entering the system s A pump runaway valve D should be installed on the air line to automatically shut off the pump if it starts to run too fast Read and follow the instructions supplied with each component in the system If the pump will be unattended for any period of time if there is an air supply interruption or at the end of the work shift shut off the system and always relieve the pressure See Pressure Relief Proce dure 306518ZAC Troubleshooting Troubleshooting EF 1 Follow Pressure Relief Procedure page 6 before checking or repairing gun 2 Check all possible problems and causes before dis assembling gun Pump fails to operate Problem Cause Solution Inadequate air supply pressure or Increase air supply and or clear restricted air lines restriction Closed or clogged valves Open and or clear Clogged fluid lines hoses valves gite Relieve pressure Clear obstruction Assess damage and service air Damaged air motor motor Exhausted fluid supply Refill and reprime or flush Continuous air exhaust Worn or damaged air motor gasket Asses wear or damage and service or seal air motor Erratic pump operation Exhausted fluid supply Refill and reprime or flush Held open or worn intake valve or piston packing2. Grounding R w N The equipment must be grounded to reduce the risk of static sparking and electric shock Electric or static sparking can cause fumes to ignite or explode Improper grounding can cause electric shock Grounding provides an escape wire for the electric current Be sure to ground all this equipment Pump Use a ground wire and clamp as shown in FIG 1 Fluid hoses Use only electrically conductive hoses Air compressor Follow manufacturer s recommenda tions Fluid supply container Follow the local code 5 C A N D A E aL To maintain grounding continuity when flushing or relieving pressure hold metal part of the valve firmly to the side of a grounded metal pail then trigger the gun valve To ground the pump remove the ground screw Z and insert through the eye of the ring terminal at end of the ground wire Y Fasten the ground screw back onto the pump and tighten securely Connect the other end of the ground wire to a true earth ground See Fig To order a ground wire clamp order Part No 222011 N FIG 1 F page ar Pala y OR L s Pa p B ES DETAIL A en T
3. and explosion from static sparking e The air bleed device relieves air trapped between it and air motor after the air supply is shut off Trapped air can cause the motor to cycle unexpectedly causing serious injury if you are adjusting or repairing the pump Use either a bleed type master air valve A or a quick disconnect coupler M and fitting L Install them near the pump air inlet within easy reach from the pump e The fluid drain H assists in relieve fluid pressure in the displacement pump hoses and dispensing valve Triggering the valve to relieve pressure may not be sufficient s The thermal relief kit R assists in relieving pressure in the pump hose and dispensing valve due to heat and expansion e The ground wire F reduces the risk of static sparking NOTICE Do not hang the air accessories directly on the air inlet E The fittings are not strong enough to support the accessories and may break Provide a bracket on which to mount the accessories NOTE Install the air line accessories in the order shown in FIG 2 306518ZAC 1 Installation Install a pump runaway valve D to shut off the air to the pump if the pump accelerates beyond the pre adjusted setting A pump that runs too fast can be seriously damaged Never allow the pump to run dry of fluid being pumped A dry pump will quickly accelerate to a high speed possibly damaging itself and it may get very hot Install an ai
4. 11 in the air motor piston 2 place the actuator 13 in the yoke 22 and place the well greased actuator yoke assembly in the piston with the trip rod going through the center holes of the actuator and yoke and the stems of the inlet valve poppets 1 going through the grommets 12 8 Thread the top of valve nuts 30 onto the stems of the inlet valve poppets 1 until one thread of the inlet valve poppets is exposed above the valve nuts 9 Install the pins 23 in the yoke 22 place the toggle arm 25 ends of the toggle assembly M onto the toggle pins and snap the pivot pin 26 ends of the toggle assembly into the piston lugs L 10 Measuring with the gauge create 0 145 inch 3 7 mm of clearance between the inlet valve poppets 1 and the piston seat when the inlet valve is open See the Cutaway View FIG 4 10 NOTE Adjust the distance between the inlet valve pop pets and the piston seat by turning the top valve nuts 30 11 Tighten the bottom valve nuts 30 by hand The grommets 12 should be slightly compressed 12 Align the holes in the valve nuts 30 and the slots on the stems of the inlet valve poppets 1 and drop the lock wires 31 through the holes in the valve nuts and into the slots in the stems of the inlet valve poppets Pull the lock wires down tightly and bend the ends with pliers so that they cannot be pulled back out of the holes Never re use the old lock wires They will get b
5. 6 in Model 203872 Series N Overall length 38 1 in Model 204254 Series S Overall length 49 9 in Model 222087 Series E Overall length 59 9 in 3 8 in npt f air inlet an a Model 203857 33 8 in 859 mm Model 203872 26 3 in 668 mm Model 204254 38 1 in 968 mm J Model 222087 48 1 in 1222 mm Dimensions 1158 mm 968 mm 1267 mm 1521 mm anana grounding screw 1 2 in npt f fluid outlet 15 Graco Standard Warranty Graco warrants all equipment referenced in this document which is manufactured by Graco and bearing its name to be free from defects in material and workmanship on the date of sale to the original purchaser for use With the exception of any special extended or limited warranty published by Graco Graco will for a period of twelve months from the date of sale repair or replace any part of the equipment determined by Graco to be defective This warranty applies only when the equipment is installed operated and maintained in accordance with Graco s written recommendations This warranty does not cover and Graco shall not be liable for general wear and tear or any malfunction damage or wear caused by faulty installation misapplication abrasion corrosion inadequate or improper maintenance negligence accident tampering or substitution of non Graco component parts Nor shall Graco be liable for malfunction damage or wear caused by the incompatibility of Graco e
6. distributor Phone 612 623 6928 or Toll Free 1 800 533 9655 Fax 612 378 3590 All written and visual data contained in this document reflects the latest product information available at the time of publication Graco reserves the right to make changes at any time without notice For patent information see www graco com patents Original instructions This manual contains English MM 306518 Graco Headquarters Minneapolis International Offices Belgium China Japan Korea GRACO INC AND SUBSIDIARIES P O BOX 1441 MINNEAPOLIS MN 55440 1441 USA Copyright 1994 Graco Inc All Graco manufacturing locations are registered to ISO 9001 www graco com Revised February 2014
7. from traffic areas sharp edges moving parts and hot surfaces Do not kink or over bend hoses or use hoses to pull equipment Keep children and animals away from work area Comply with all applicable safety regulations TOXIC FLUID OR FUMES HAZARD Toxic fluids or fumes can cause serious injury or death if splashed in the eyes or on skin inhaled or swallowed e Read MSDSs to know the specific hazards of the fluids you are using e Store hazardous fluid in approved containers and dispose of it according to applicable guidelines e Always wear chemically impermeable gloves when spraying dispensing or cleaning equipment MOVING PARTS HAZARD Moving parts can pinch cut or amputate fingers and other body parts s Keep clear of moving parts s Do not operate equipment with protective guards or covers removed e Pressurized equipment can start without warning Before checking moving or servicing equipment follow the Pressure Relief Procedure and disconnect all power sources PERSONAL PROTECTIVE EQUIPMENT Wear appropriate protective equipment when in the work area to help prevent serious injury including eye injury hearing loss inhalation of toxic fumes and burns This protective equipment includes but is not limited to e Protective eyewear and hearing protection e Respirators protective clothing and gloves as recommended by the fluid and solvent manufacturer 306518ZAC 3 Installation Installation
8. items 101 to 114 Model 203872 Series N 16 gal Includes items 101 to 113 and 115 Model 203876 Series N Universal Includes items 101 to 112 Model 204254 Series S 55 gal Bung Mount Includes items 101 to 113 116 and 118 Model 222087 Series E 275 gal Bung Mount Includes items 101 to 113 117 and 118 Air Motor Ref Part Description Qty 1 VALVE poppet 2 2 160614 PISTON air motor 1 4 116343 SCREW grounding1 1 5 238278 BASE air motor includes 5a 1 5a 116343 SCREW grounding 1 6 PACKING u cup 1 8 15H889 ROD displacement 1 9 O RING buna N 1 10 160624 O RING buna N 1 11 203965 ROD trip 1 12 GROMMET rubber 2 13 172867 ACTUATOR valve 1 14 172866 CLIP spring 2 15 102975 SCREW rd hd mach no 6 32 x 2 1 4 6 3mm 16 POPPET valve 2 17 160613 CYLINDER air motor 1 18 PLATE identification with muffler 1 19 SCREW hex head no 8 32 x 0 38 12 inches 10 mm long 20 PLATE warning with muffler 1 21 101578 SCREW hex head 5 16 18 x 0 88 6 306518ZAC 191128 TUBE extension 21 75 553 mm 191126 TUBE extension 14 25 362 mm 191130 TUBE extension 26 0 661 mm 191131 TUBE extension 36 0 915 mm 104542 SCREW cap hex hd M8 x 1 25 Ref Part 22 158360 23 158362 24 25 160623 26 158364 27 167585 28 156698 29 161435 30 31 33 160932 Pumps Ref Part 104 105 191125 106 157182 107 183009 108 109 101190 110 191122 111 100279 112 113 110
9. of the air motor base 5 Carefully inspect the smooth inner surface on the cylinder for scoring or irregular surfaces Such damage causes premature packing wear and leaking so replace the part if it is damaged 6 Using wrenches on the flats of the displacement rod 8 and on the flats of the fluid piston 11 unscrew the fluid piston from the displacement rod 7 Take the ball 111 out of the displacement rod 8 and take the packing o ring 104 off of the fluid pis ton 8 Clean and inspect all parts Use all the repair kit parts during reassembly and replace other parts as necessary 9 Place the piston ball 109 in the displacement rod 8 10 Install the new packing o ring 104 on the fluid pis ton 110 11 Clamp the flats of the fluid piston 110 in a vise and torque the displacement rod 8 to the piston to 40 to 60 ft lbs 54 to 81 N m 12 Clamp the air motor base 5 in a vise horizontally by closing the vise jaws on the flange 13 Use a strap wrench to screw the displacement pump cylinder 105 to the air motor base 5 and torque to 95 to 105 ft lbs 129 to 142 N m 14 If the ground wire was disconnected before servic ing be sure to reconnect it before you operate the pump Air Motor and Throat Service Refer to FIG 3 and FIG 4 for the following instructions ki O Pump Repair Kit 238286 is available and includes repair parts for the pump and air motor Use all parts in the ki
10. pressure Start and Adjusting the Pump K amp ag 1 With the air regulator C closed open the bleed type master air valves A or if so equipped join the quick disconnect coupler M to the male fit ting L 2 Open the dispensing valve J into a grounded metal waste container making firm metal to metal contact between the container and valve 3 Open the pump air regulator C slowly just until the pump is running When the pump is primed and all air has been pushed out of the lines close the dis pensing valve NOTE When the pump is and with sufficient air sup plied the pump starts when the dispensing valve is opened and shuts off when closed 4 Adjust the air regulator until you get sufficient flow from the dispensing valve Always run the pump at the lowest pressure necessary to get the desired results Do not exceed the maximum working pres sure of any component in the system If your pump accelerates quickly or is running too fast stop it immediately and check the fluid supply If the supply container is empty and air has been pumped into the lines prime the pump and lines with fluid or flush it and leave it filled with a compat ible solvent Be sure to eliminate all air from the fluid lines NOTICE Never allow the pump to run dry of the fluid being pumped A dry pump will quickly accelerate to a high speed possibly damaging itself and it may get very hot NOTE
11. surface of the trip rod can result in erratic air motor operation Use the special padded pliers to grasp the rod Fic 3 iM l 13 Remove the o ring 24 from the air motor piston 2 10 Remove the six screws 21 holding the air motor cylinder 17 to the air motor base 5 and carefully 14 Clamp the displacement rod upright in the vise by pull the cylinder straight up off the piston 2 closing the vise jaws on the flats of the displace ment rod 15 Use a screw driver to push down on the trip rod To avoid damaging the cylinder wall lift the cylinder yoke 22 to snap the toggles M down FIG 4 straight up off the piston Never tilt the cylinder while you are removing it 16 Remove the lockwires 31 from the adjusting nuts 30 of the transfer valves Screw the top nuts off Screw the valve poppet 1 stems out of the grom mets 12 and bottom nuts 30 Take the valve pop pets off the stems and squeeze them firmly to check for cracks 11 Pull the air motor piston displacement rod assembly 2 8 clear of the air motor base 5 by pulling up on the air motor piston 12 Remove the o rings 9 112 and u cup packing 6 from the air motor base 5 Use needle nose pliers to remove the u cup packing from the bottom of the air motor base 17 Grip the toggle rockers 26 with pliers Compress the springs 27 and swing the toggle assembly M up and away from the piston lugs L and remove the a
12. 127 114 115 116 117 118 222308 118a 118b 210834 Description YOKE rod trip PIN toggle O RING nitrile rubber ARM toggle ROCKER toggle SPRING helical compression O RING buna N NUT cylinder cap NUT adjusting LOCK WIRE transfer valve GASKET copper Description PACKING o ring CYLINDER fluid RETAINER ball BODY intake valve O RING buna N BALL steel 1 25 mm dia PISTON fluid BALL steel 0 88 22 2 mm dia O RING buna N SPACER foot BUNG ADAPTER ASSEMBLY includes items 118a and 118b ADAPTER bung bare Parts Q lt le r lt D A MMM ND M b k k dt k k k ed k k k k k Parts included in Kit 238286 purchase separately Parts included in Kit 222559 purchase separately NOTE Two accessory tools are required for air motor and throat services Padded Pliers 207579 and Gauge 17181 13 Technical Data Technical Data 5 1 Fire Ball 300 Pumps US Metric Maximum fluid working pressure 900 psi 6 2 MPa 62 bar Fluid pressure ratio 5 1 Air pressure operating range 40 to 180 psi 0 28 to 1 2 MPa 2 8 to 12 bar Maximum air consumption Pump cycles per gallon liters 13 ft minute for first gom pumped at 100 psi up to 8 addi tional ft min for each additional gpm with pump operated within recommended range 30 0 096 m minute for first Ipm pumped at 0 7 MPa 7 bar up to 0 058 additional m min for each addition
13. ES K _ CTT SE J T 1 2 in 13 mm between foot spacer and bottom of E S drum FIG 2 Typical Installation Key A Bleed type master air valve required if quick disconnect H Drain valve required Order Part No 210658 fitting L and coupler M are not installed Order Part No J Dispensing valve 107142 K Low level cut off valve B Airline filter L Male quick disconnect fitting C Air regulator and gauge M Female quick disconnect coupler D Pump runaway valve N Airline lubricator E Airinlet P Fluid hose F Ground wire required Order Part No 222011 R Thermal relief kit required Order Part No 237893 G Pump model 204254 shown S Bung adapter models 204254 and 222087 x 306518ZAC 1 Install the pump on the drum cover so that the pump s fluid intake is 1 2 inch 13 mm off the bot tom of the drum FIG 2 2 On Models 204254 and 222087 screw the bung adapter tightly into the drum Covers bung hole adjust the position of the pump in the drum and tighten the bung adapter screw to hold the pump System Accessories Refer to Fic 2 for the following instructions AS Four accessories are required in your system an air shut off valve air bleed device fluid drain valve thermal relief kit and ground wire These accessories help reduce the risk of serious bodily injury including fluid injection splashing in the yes or on the skin injury from moving parts if you are adjusting or repair the pump
14. Instructions G GRACO 5 1 Fire Ball 300 Pu m p 30651 patr For pumping non corrosive and non abrasive greases and lubricants only For professional use only Model No 203872 203857 204254 222087 203876 900 psi 6 2 MPa 62 bar Maximum Working Pressure 180 psi 1 2 MPa 12 bar Maximum Air Input Pressure Read all warnings and instructions in this manual Save these instructions Important Safety Instructions A 7 S vA K KORL Gelki A T MHN ATAL HOM W PROVEN QUALITY LEADING TECHNOLOGY U W CE Contents WarningS 225 s e e x e x e er messe 3 Installation d Grounding e e eiaa Ea H RTE a Z BT dE d System Accessories 5 Operation ac i ieee NN Se LRE 6 Pressure Relief Procedure 6 Start and Adjusting the Pump 6 Troubleshooting 7 Service 24002 beh Vd ae Ae a A Oe ee 8 Displacement Pump Service 8 Air Motor and Throat Service 8 Parts sind dattes Seid Adele eme 12 Technical Data 14 Dimensions 15 Graco Standard Warranty 16 2 306518ZAC Warnings Warnings The following warnings are for the setup use grounding maintenance and repair of this equipment The exclama tion point symbol alerts you to a general warning and the hazard symbols refer to pro
15. OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE IN CONNECTION WITH ACCESSORIES EQUIPMENT MATERIALS OR COMPONENTS SOLD BUT NOT MANUFACTURED BY GRACO These items sold but not manufactured by Graco such as electric motors switches hose etc are subject to the warranty if any of their manufacturer Graco will provide purchaser with reasonable assistance in making any claim for breach of these warranties In no event will Graco be liable for indirect incidental special or consequential damages resulting from Graco supplying equipment hereunder or the furnishing performance or use of any products or other goods sold hereto whether due to a breach of contract breach of warranty the negligence of Graco or otherwise FOR GRACO CANADA CUSTOMERS The Parties acknowledge that they have required that the present document as well as all documents notices and legal proceedings entered into given or instituted pursuant hereto or relating directly or indirectly hereto be drawn up in English Les parties reconnaissent avoir convenu que la r daction du pr sente document sera en Anglais ainsi que tous documents avis et proc dures judiciaires ex cut s donn s ou intent s a la suite de ou en rapport directement ou indirectement avec les proc dures concern es Graco Information For the latest information about Graco products visit www graco com TO PLACE AN ORDER contact your Graco distributor or call to identify the nearest
16. al lpm with pump oper ated within recommended range 7 9 Recommended speed for optimum pump life 70 cycles per minute Maximum recommended pump speed Wetted Parts 130 cycles per minute 5 gpm Steel aluminum 130 cycles per minute 19 lpm buna N urethane Sound pressure level measured at 1 meter 77 8 dB A from unit Sound power level tested in accordance with 85 6 dB A ISO 9614 2 Approximate weight 17 Ib 7 7 kg Loctite is a registered trademark of the Loctite Corporation psi scfm bar KS m min 450 107 10 31 4 0 3 Inlet Air Pressures 100 psi 2 300 z 6 9 bar Nn M 21 5j R Oaks 150 g 4 8 bar 104 A 17 S 40 psi S ER E 2 8 bar O 5 2 0 12 gt a 0 2 gpm 1 J 3 4 0 08 Ipm 3 8 7 6 11 15 TEST FLUID No 10 Weight Oil 14 306518ZAC Dimensions Model 203876 Series N Overall length 20 7 in 526 mm grounding screw 3 8 in npt f air inlet 77 1 2 in npt f 8 9 in fluid outlet 226 mm lt Overall Length 20 7 in 526 mm Mounting Hole Layout Q Gasket Part No 161023 Two 0 265 in 6 73 mm diameter holes on 5 in 127 mm bolt circl amp our 0 265 in 6 73 mm diameter holes on aiin 5 in 127 mm FN O tite 3 in 76 2 mm diameter hole e 2 Hole Mounting Pattern 306518ZAC 4 Hole Mounting Pattern Model 203857 Series N Overall length 45
17. cedure specific risks When these symbols appear in the body of this manual or on warning labels refer back to these Warnings Product specific hazard symbols and warnings not covered in this section may appear throughout the body of this manual where applicable RA EQUIPMENT MISUSE HAZARD Misuse can cause death or serious injury e Do not operate the unit when fatigued or under the influence of drugs or alcohol s Do not exceed the maximum working pressure or temperature rating of the lowest rated system com ponent See Technical Data in all equipment manuals e Use fluids and solvents that are compatible with equipment wetted parts See Technical Data in all equipment manuals Read fluid and solvent manufacturer s warnings For complete information about your material request MSDS from distributor or retailer e Do not leave the work area while equipment is energized or under pressure e Turn off all equipment and follow the Pressure Relief Procedure when equipment is not in use e Check equipment daily Repair or replace worn or damaged parts immediately with genuine manu facturer s replacement parts only e Do not alter or modify equipment Alterations or modifications may void agency approvals and create safety hazards Make sure all equipment is rated and approved for the environment in which you are using it Use equipment only for its intended purpose Call your distributor for information Route hoses and cables away
18. e flange Do not damage the plated surface of the trip rod 11 25 Use a strap wrench to screw the displacement Damaging the surface of the trip rod can result in pump cylinder 105 to the air motor base 5 and erratic air motor operation Use the special padded torque to 95 to 105 ft lbs 129 to 142 N m pliers to grasp the rod 26 Before remounting the pump connect an air hose l and run the air motor slowly starting with just 8 make sure it operates smoothly 22 Clean the threads of the fluid piston 110 apply 27 Reconnect the ground wire before you resume regu Loctite to the threads install the new packing lar pump operation o ring 104 on the fluid piston and thread the fluid piston onto the displacement rod 8 11 22 M K 2 rA 127 a 11 AN Le NS Q 30 A A AX Sy BREA 12 ee NCE gt TN NI na D 14 16 30 A Push toggles M in and then up A Cut off tops of poppets as indicated by dotted lines A Turn wires up A 0 145 in 3 7 mm clearance between poppets 1 and seat when it is open FIG 4 306518ZAC 11 Parts Parts Air Motor 114 115 116 or 117 lt I 19 A Lips face down 12 306518ZAC Model 203857 Series N 55 gal Includes
19. quipment with structures accessories equipment or materials not supplied by Graco or the improper design manufacture installation operation or maintenance of structures accessories equipment or materials not supplied by Graco This warranty is conditioned upon the prepaid return of the equipment claimed to be defective to an authorized Graco distributor for verification of the claimed defect If the claimed defect is verified Graco will repair or replace free of charge any defective parts The equipment will be returned to the original purchaser transportation prepaid If inspection of the equipment does not disclose any defect in material or workmanship repairs will be made at a reasonable charge which charges may include the costs of parts labor and transportation THIS WARRANTY IS EXCLUSIVE AND IS IN LIEU OF ANY OTHER WARRANTIES EXPRESS OR IMPLIED INCLUDING BUT NOT LIMITED TO WARRANTY OF MERCHANTABILITY OR WARRANTY OF FITNESS FOR A PARTICULAR PURPOSE Graco s sole obligation and buyer s sole remedy for any breach of warranty shall be as set forth above The buyer agrees that no other remedy including but not limited to incidental or consequential damages for lost profits lost sales injury to person or property or any other incidental or consequential loss shall be available Any action for breach of warranty must be brought within two 2 years of the date of sale GRACO MAKES NO WARRANTY AND DISCLAIMS ALL IMPLIED WARRANTIES
20. r line lubricator N for automatic air motor lubrication Install a bleed type master air valve A to relieve air trapped between the valve and the motor As an alternative you can install an air line quick discon nect coupler M and fitting L to serve as an air bleed device See Fic 2 Install a Thermal Relief Kit K on the dispensing valve side of the pump Install the air regulator C to control pump speed and pressure Install an air line filter B to remove harmful dirt and contaminants from the compressed air supply Install another bleed type master air valve A to iso late the accessories for servicing Install a drain valve H near the pump fluid outlet Install a suitable fluid hose P and dispensing valve J Operation Operation Pressure Relief Procedure Follow the Pressure Relief Procedure whenever you see this symbol K x A i S This equipment stays pressurized until pressure is manually relieved To help prevent serious injury from pressurized fluid such as skin injection splashing fluid and moving parts follow the Pressure Relief Procedure when you stop spraying and before cleaning checking or servicing the equipment 1 Close the pump air regulator and bleed type master air valve required in the system 2 Hold a metal part of the dispensing valve firmly to a grounded metal waste container and trigger the valve to relieve the fluid
21. rittle and break easily from too much bending 13 Take the assembly out of the vise so that you can move it around for the next two steps 14 Grease and install the new o rings 9 24 112 15 Install the new u cup packing 6 through the bottom of the air motor base with the lips facing toward the bottom of the pump 16 Slide the displacement rod 8 down through the packings and lower the air motor piston 2 into the air motor base 5 17 Clamp the air motor upright in the vise by closing the vise jaws below the flange 18 Carefully lower the air motor cylinder 17 straight down onto the piston assembly 2 Tighten the six screws 21 holding the air motor cylinder to the air motor base 5 To avoid damaging the cylinder wall lower the cylin der straight down onto the piston Never tilt the cylin der as it is being lowered 19 Pull the trip rod 11 so it is sticking up out of the air motor cylinder 17 NOTE You may have to hold the unit upside down to shake the trip rod loose 306518ZAC Service 20 Grip the trip rod 11 with padded pliers screw the 23 Clamp the flats of the fluid piston 11 in a vise and cylinder cap 29 onto the trip rod push the cylinder torque the displacement rod 8 to the piston to 40 to cap nut down and screw it into the top of the cylin 60 ft lbs 54 to 81 N m der 24 Clamp the air motor base 5 in a vise horizontally by closing the vise jaws on th
22. s Clear and service Pump operates but output low on upstroke Held open or worn piston packings Clear and service Pump operates but output low on Pump operates but output low on both strokes Held open or worn intake valve Clear and service downstroke Inadequate air supply or restricted Increase air supply and or clear air line restriction Closed or clogged valves Open and or clear Refill fluid supply and reprime pump Exhausted fluid supply or flush Clogged fluid lines hoses valves etc Relieve pressure Clear obstruction 306518ZAC Service Service Displacement Pump Service AA Pump Repair Kit 238286 is available and includes repair parts for the pump and air motor Use all parts in the kit for best results 1 Flush the pump 2 Relieve the pressure before proceeding page 6 3 Disconnect the hoses remove the pump from its mounting and clamp the air motor base 5 in a vise horizontally by closing the vise jaws on the flange 4 Unscrew the intake valve body 107 from the fluid cylinder 105 Disassemble the intake valve See Parts Drawing Page 12 Clean and inspect the parts for wear or damage and replace parts as needed be sure to check the o ring 108 Unless further intake valve service is needed reassemble and reinstall using liquid sealant on the male threads 5 Use strap wrench on the fluid cylinder 105 to screw it out
23. ssembly Check that the valve actuator 13 is support by the spring clips 14 but slides easily into them FIG 4 18 Remove the trip rod yoke 22 actuator 13 and trip rod 11 Check the exhaust valve poppets 16 for cracks 19 To remove the exhaust valve poppets 16 stretch them out and cut them with a sharp knife 306518ZAC 9 Service Reassembly 1 Clean all the parts carefully in a compatible solvent and inspect for wear or damage Use all the repair kit parts during reassembly and replace other parts as needed 2 Check the polished surfaces of the piston 2 dis placement rod 8 and cylinder 17 wall for scratches or wear A scored rod causes premature throat seal wear and leaking 3 Lubricate all parts with a light water resistant grease 4 Clamp the displacement rod 8 upright in the vise by closing the vise jaws on the flats of the displace ment rod 5 Pull the exhaust valve poppets 16 into the value actuator 13 and clip off the top part shown with dotted lines in FIG 4 6 Install the new grommets 12 in the actuator 22 place the inlet valve poppets 1 in the piston and thread the bottom valve nuts 30 onto the stems of the inlet valve poppets until there are a few threads left before the threads run out NOTE If you thread the valve nuts too far down onto the poppets they will run off of the threaded part of the pop pets 7 Grease heavily and place the trip rod
24. t for best results Two accessory tools should be used Padded Pliers 207579 are used to grip the trip rod without damaging its surface Gauge 171818 is used to ensure the proper clearance between the poppets and seat of the transfer valve Disassembly 1 Flush the pump 2 Relieve the pressure see page 6 3 Disconnect the ground wire from the grounding screw 5a disconnect the hoses remove the pump from its mounting and clamp the air motor base ina vise horizontally by closing the vise jaws on the flange 4 Use a strap wrench on the fluid cylinder 105 to screw it out of the air motor base 5 5 Pull the displacement rod 8 down as far as it will go FIG 3 306518ZAC Service 6 Using wrenches on the flats of the displacement rod 8 and on the flats of the fluid piston 110 unscrew the fluid piston from the displacement rod Remove the ball 111 from the end of the displacement rod and remove the packing o ring 104 from the fluid piston 7 Clamp the air motor upright in the vise by closing the vise jaws below the flange 8 Unscrew the cylinder cap nut 29 from the top of the air motor cylinder 17 9 Pull up on the cylinder cap nut 29 to expose the trip rod grasp the trip rod with padded pliers and unscrew the cylinder cap nut from the trip rod NOTICE Do not damage the plated surface of the trip rod 11 Damaging the
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